Limitations in the Grain Boundary Processing of the Recycled HDDR Nd-Fe-B System

Fully dense spark plasma sintered recycled and fresh HDDR Nd-Fe-B nanocrystalline bulk magnets were processed by surface grain boundary diffusion (GBD) treatment to further augment the coercivity and investigate the underlying diffusion mechanism. The fully dense SPS processed HDDR based magnets were placed in a crucible with varying the eutectic alloys Pr(68)Cu(32) and Dy(70)Cu(30) at 2–20 wt. % as direct diffusion source above the ternary transition temperature for GBD processing followed by secondary annealing. The changes in mass gain was analyzed and weighted against the magnetic properties. For the recycled magnet, the coercivity (H(Ci)) values obtained after optimal GBDP yielded ~60% higher than the starting recycled HDDR powder and 17.5% higher than the SPS-ed processed magnets. The fresh MF-15P HDDR Nd-Fe-B based magnets gained 25–36% higher coercivities with Pr-Cu GBDP. The FEG-SEM investigation provided insight on the diffusion depth and EDXS analysis indicated the changes in matrix and intergranular phase composition within the diffusion zone. The mechanism of surface to grain boundary diffusion and the limitations to thorough grain boundary diffusion in the HDDR Nd-Fe-B based bulk magnets were detailed in this study.